Hand knotted Carpet / Rugs Production process.
Eventually, the hand-knotted carpets and rugs are seen to be made all over the world. The quintessential style of carpets, hand knotted was originally seen in Asiatic locations. These highly prized specimens of floor coverings were later imitated by the European nations later. Such carpets are constructed by clipping the lengths of yarn. The clipped ends of the yarn form the pile of the carpet that are tied in rows crossways to warps. Each row of knots is separated by multiple picks of wefts, fixed in as interchanging series of plain weave.
There are various types of hand knotting techniques. They are as follows:
· Turkish knot, or the symmetrical, or Ghiordes.
· Persian knot, or the asymmetrical, or Senneh.
· Jufti knot, or the resultant of the unison of Turkish and Persian but done on four weft strands, instead of two.
· Spanish knot, or solo warp symmetrical knot
Famous hand knotted Persian, Turkish specimens of carpets and rugs have been fascinating the world since centuries. Till today, there is a huge demand of such beauties in the Western markets. Materials such as cotton, silk, wool, and jute have also been used to knot such handmade marvels.
"A Floor Covering which is made completely by human hands by Handknotting, Handtufting or Handweaving, in which handspun Yarn of natural fibers (most commonly wool or silk) is used, , with individual character and design."
Hand-made carpets are traditionally more expensive than those made by machines. Though there are several carpet-making methods, including braiding, hand tying (or hand knotting), hooking, shearing and tufting, the most common of these are braiding and hand knotting.
1. Designing / Mapping:
The first step in making a custom rug, whether it is hand knotted or hand tufted, is preparing the design map. This is a crucial step, as it will determine the final outcome quality. Our expert designers spend as much time as necessary making sure their map is perfect. We can do it by hand or per computer, depending on the type of design and the final effect desired by the customer. For hand knotted rugs we usually draw our design maps with the help of computer software in which we can specify each knot and make sure it is the way our customer wants to have it. The resulting CAD will create a weaving graph for our weavers to follow later.
2. Dyeing The Yarn / Color Matching:
This is how we select the colors for the varied yarn that we offer for our custom rugs and how we dye them. Whether you choose to have your rug handmade in linen, bamboo silk, hemp, nettle or recycled PET, for a Rug of Your Life you can always choose the colors you want for your rug. When we receive your design and color preferences, if different than the colors on the design, we start looking for the closest possible matches in our Pantone and ARS color guides.
3. Weaving:
The design is then woven following the design map or weaving graph. Often several skilled weavers will sit and work together on the rug at the same time. The rug is created by carefully knotting the right color on the right spot on the warp. The weavers move their hands very precisely and quickly, while paying close attention to each knot's color.
4. Clipping:
After weaving, washing and stretching, the yarn needs to be cut at the right length and details as Clipping / carving or embossing are applied.
5. Washing:
Once the carpet is completely woven, it comes off the loom and goes through a soft, but vigorous washing process with water and neutral detergents. This process removes dust and small yarn pieces. It will leave the carpet completely clean and it is important to maintain and care for the carpet by vacuum cleaning it regularly once you have it.
6. Stretching:
After washing, the carpet is stretched in order to balance the handmade knots and create a perfectly flat-laying surface. This is the best way for the rug to dry and get its final shape and exact size.
7. Binding:
You can choose whether you want to keep the fringe of your custom hand knotted carpet or if you prefer it bound. The binding is done either in one of the design colors, in a completely different one, or following the design colors all around for a continuous pattern. In any case, it is always our binding master who very skillfully creates the perfect frame for your rug.
8. Finishing:
Once all the Process are done. Carpet goes for QC (quality Check) and Then inspection is done for color matching, Design Matching and Weaving Quality, Color fastness, when everything goes good, later forwarded for next step that is packing.
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